KR101941430B1 - Car mat using polyolefin resin and manufacturing method thereof - Google Patents

Abstract

The present invention relates to a vehicle mat which can be recycled through the use of a polyolefin resin to produce a sheet layer, a single layer and an adhesive layer of an automotive mat which is environmentally friendly and recyclable, as well as satisfying physical properties of a vehicle mat, And a method for producing the same.
In order to accomplish the above object, the present invention provides a vehicle mat which can be recycled through a single material using a polyolefin resin, and a method of manufacturing the same, wherein a polyolefin elastomer and a polypropylene are mixed together in a ratio of 1: 1 A second step of adding a foaming agent to the resin mixture to produce a lower-layer sheet portion through thermal decomposition of the foaming agent in a temperature range of 200 to 220 占 폚; And a fourth step of laminating the lower layer sheet portion and the upper layer carpet portion using a hot-melt film adhesive made of a polyolefin-based elastomer, wherein the foaming agent is at least one selected from the group consisting of azodicarbonamide Azodicarbonamide, ADCA, (CON NH _{2) 2)} wherein the resin-based mixture comprising a resin mixture is the At least one of ethylene-vinyl acetate copolymer (EVA) of 30 phr to 40 phr (phr: parts per hundred resin), 100 phr to 200 phr of calcium carbonate and 5 phr to 8 phr of process oil As a technical point.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to a mat for a vehicle which can be recycled through a single material using a polyolefin resin,

The present invention relates to a vehicle mat which can be recycled through the use of a polyolefin resin, and more particularly, to a vehicle mat which is excellent in flame retardancy and abrasion resistance, thereby satisfying physical properties of a vehicle mat and being environmentally friendly and recyclable. The present invention relates to a mat for a vehicle which can be recycled through the use of a single material using a polyolefin resin and a method of manufacturing the same.

Generally, a car is a typical transportation means, vibration occurs from the floor when moving, and external noise is transmitted to the interior of the vehicle through a roof, a door, a window, etc., and foreign dust or foreign matter may be introduced have. Therefore, a mat for a vehicle which is easy to remove foreign substances as well as vibration and noise reduction is required. In addition to the above effect, a role of giving a good feel of the foot cloud in place is also required. Therefore, in the auxiliary mat for a car, a carpet (carpet) form has been usefully used for imparting cushioning property, adhesion property, sound absorption property and warming property.

Currently, there are two methods for manufacturing automotive mats. One is the method of manufacturing automobile mats by molding the polyurethane foam through the primary molding process and the secondary foam molding process. The molding process and the secondary molding are performed by forming the PU FOAM PAD by a foaming process using the EPP PAD together, and then attaching the sheet layer and the single layer with hot melt.

Particularly, the sheet layer contacting with the bottom of the vehicle is manufactured using PVC or recycled scrap resin, the nylon yarn is used as the raw layer, and the adhesive layer for bonding the sheet layer and the raw layer is a solvent type or solution type adhesive .

However, such conventional techniques are harmful to the human body due to the generation of harmful substances including volatile organic compounds (TVOC), and since the sheet layer and the monolayer are made of different materials, they must be completely separated when recycled, A large amount of external force is required, and there is a problem of exposure to harmful substances.

In addition, nylon used in the monolayer has physical properties such as strength, flexibility, and abrasion resistance, but it has a problem in that the production cost is increased due to the inexpensive cost, and recycling is difficult.

(Utility Model Document 1) Utility Model Registration No. 20-0358658 (August 03, 2004)

Disclosure of the Invention The present invention has been conceived to solve the above-mentioned problems, and it is an object of the present invention to provide a vehicle mat which can be recycled through the use of an environmentally friendly polyolefin resin without harmful substances including volatile organic compounds, The purpose is to provide.

Meanwhile, the object of the present invention is not limited to the above-mentioned objects, and other objects not mentioned can be clearly understood from the following description.

In order to accomplish the above object, the present invention provides a vehicle mat which can be recycled through a single material using a polyolefin-based resin, and a method of manufacturing the same, wherein the polyolefin-based elastomer and the polypropylene are mixed in a ratio of 1: A second step of adding a foaming agent to the resin mixture to produce a lower-layer sheet portion through thermal decomposition of the foaming agent within a temperature range of 200 to 220 占 폚, and a second step of producing an upper-layer carpet portion by using a polypropylene yarn And a fourth step of laminating the lower layer sheet portion and the upper layer carpet portion using a hot melt film adhesive made of a polyolefin elastomer, wherein the foaming agent is selected from the group consisting of azodicarbonamide (ADCA) having a thermal decomposition temperature of 200 ° C or higher, , (NH ₂ CON) ₂ ) system, wherein the resin mixture comprises At least one of ethylene-vinyl acetate copolymer (EVA) of 30 phr to 40 phr (phr: parts per hundred resin), 100 phr to 200 phr of calcium carbonate, and 5 phr to 8 phr of process oil .

Preferably, the resin mixture prepared in the first step further comprises an antioxidant and zinc stearate, and the content of the antioxidant and the zinc stearate is in the range of Are each 0.2 to 0.5 phr.

Preferably, the resin mixture prepared in the first step further comprises at least one of an ethylene-vinyl acetate copolymer (EVA), calcium carbonate and a process oil. .

Preferably, the polypropylene yarn in the third step is a high-fineness polypropylene yarn of 2,600 to 2,800 denier which is produced by yarn-spun yarn of 1,300 to 1,400 denier low-fineness polypropylene, respectively.

Preferably, the vehicle mat produced by the method of any one of claims 1 to 4 is pulverized and extruded to be recycled as a separate lower-layer sheet portion.

According to a solution to the above problems, a vehicle mat which can be recycled through the use of a single material using the polyolefin-based resin of the present invention and a method for producing the same can be produced by manufacturing a lower layer sheet portion with a resin mixture containing a polyolefin- And the lower layer sheet portion and the upper layer carpet portion are joined together with an adhesive made of a polyolefin-based elastomer, so that harmful substances including volatile organic compounds are not generated, which is harmless to the human body.

Since the polyolefin elastomer and polypropylene which is a polyolefin material are unified, it can be recycled by crushing and extruding the whole without separating at the time of disposal, which is advantageous in that it is environmentally friendly and industrial waste is not generated.

FIG. 1 is a flow chart illustrating a method of manufacturing a recyclable vehicle mat according to an embodiment of the present invention by uniting a material using a polyolefin resin.
2 is a graph showing tensile strengths of a lower sheet portion made of a resin mixture in which a polyolefin elastomer and a polypropylene are mixed according to an embodiment of the present invention.
3 is a graph showing an elongation percentage of a lower-layer sheet portion made of a resin mixture in which a polyolefin-based elastomer and a polypropylene are mixed according to an embodiment of the present invention.
4 is a graph showing the tensile strength of a lower sheet portion made of a resin mixture further comprising EVA according to an embodiment of the present invention.
5 is a graph showing elongation of a lower sheet portion made of a resin mixture further comprising EVA according to an embodiment of the present invention.
6 is a graph showing tensile strength of a lower sheet portion made of a resin mixture containing calcium carbonate and EVA according to an embodiment of the present invention.
FIG. 7 is a graph showing elongation of a lower sheet portion made of a resin mixture containing calcium carbonate and EVA according to an embodiment of the present invention. FIG.
8 is a graph showing the tensile strength of a lower sheet portion made of a resin mixture further comprising process oil, calcium carbonate and EVA according to an embodiment of the present invention.
9 is a graph showing elongation of a lower sheet portion made of a resin mixture further comprising process oil, calcium carbonate and EVA according to an embodiment of the present invention.
10 is a graph showing the decomposition temperature and decomposition time of the foaming agent according to an embodiment of the present invention.
FIG. 11 is a photograph showing a comparison between cells of a lower-layer sheet portion according to an embodiment of the present invention, according to the content of a blowing agent.
12A is a photograph showing a result of a primary antibacterial test of a lower-layer sheet portion according to an embodiment of the present invention.
12 (b) is a photograph showing a result of a secondary antibacterial test of a lower-layer sheet portion according to an embodiment of the present invention.
13 is a view showing a result of a laminating test for bonding a lower layer sheet portion and an upper layer carpet portion according to an embodiment of the present invention.
14A is a photograph showing a front view of a vehicle mat according to an embodiment of the present invention before it is processed.
14 (b) is a photograph showing a rear view of the vehicle mat according to an embodiment of the present invention before the vehicle mat is processed.
15A is a photograph showing a front view of a vehicle mat according to an embodiment of the present invention after being machined.
Fig. 15B is a photograph showing a rear view of the vehicle mat according to an embodiment of the present invention after being machined.
16 is a photograph showing a recycle sheet for recycling a mat for a vehicle according to an embodiment of the present invention.
17 is a graph showing tensile strengths of a mat and a recycle sheet for a vehicle according to an embodiment of the present invention.
18 is a graph showing the elongation of a mat for a vehicle and a recycled sheet according to an embodiment of the present invention.
19 is a graph showing the surface hardness of a vehicle mat and a recycled sheet according to an embodiment of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS The advantages and features of the present invention and the manner of achieving them will become apparent with reference to the embodiments described in detail below with reference to the accompanying drawings. However, the present invention is not limited to the embodiments described below, but may be embodied in various different forms, and these embodiments are not intended to be exhaustive or to limit the scope of the present invention to the precise form disclosed, It is provided to inform the person completely of the scope of the invention.

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings.

As shown in FIG. 1, a method for manufacturing a recyclable vehicle mat through unitization of a material using a polyolefin resin according to an embodiment of the present invention includes a first step (S100) of producing a resin mixture, A second step S200, a third step S300 of manufacturing an upper layer carpet portion, and a fourth step S400 of joining the lower layer sheet portion and the upper layer carpet portion together.

First, in a first step S100, a resin mixture comprising a polyolefin elastomer and polypropylene in a mixing ratio of 1: 1 is prepared.

Here, the polyolefin refers to the kind of synthetic resin, and is an organic material synthesized by adding and polymerizing an olefin which is a hydrocarbon containing one double bond per molecule.

Polyolefins are not only lighter than conventional plastic materials, but also have high transparency and water absorption properties. Further, since it is possible to regenerate and there is no toxic component in the human body, it is in the spotlight as an eco-friendly material.

An elastomer is a polymer having an elasticity and a durability. The elastomer is stretched when an external force is applied and stretched when the external force is removed. The elastomer has an intermediate shape between rubber and plastic.

Polypropylene is a typical hydrophobic material composed only of carbon and hydrogen. It has low specific gravity and is light and does not generate static electricity. Because of low water content, it does not cause contamination and bacteria can not be generated. In addition, polypropylene has excellent thermal insulation due to low thermal conductivity and is excellent in chemical resistance, abrasion resistance, elasticity, friction coefficient and tensile strength, and is lower in price than polyethylene terephthalate (PET) or nylon.

However, since polypropylene has poor resistance to stretching during stretching in a molten state, there is a problem that sheet extrusion processing is not smooth.

In order to solve the problem of polypropylene, it is preferable to use polypropylene mixed with polyolefin resin having excellent elasticity and durability.

In addition, the resin mixture prepared in the first step (S100) may further contain an antioxidant and zinc stearate.

Herein, the antioxidant is added to prevent or suppress the deterioration, aging, and decay of the resin due to oxidation, thereby increasing the aging resistance and improving the physical properties.

Zinc stearate is a zinc salt of stearic acid (C18H36O2). It is used as a lubricant for stabilizing a mixture and controlling viscosity and facilitating processing.

The resin mixture prepared in the first step S100 may further contain at least one of ethylene-vinyl acetate copolymer (EVA), calcium carbonate and process oil.

Here, the ethylene vinyl acetate copolymer is excellent in compatibility with other resins, has excellent solvent solubility, and is excellent in flexibility, adhesiveness and foamability.

The addition of calcium carbonate prevents the occurrence of sheet seizure and shrinkage, and also has an effect of flame retardancy.

The process oil is excellent in compatibility with other resins and has an advantage of improving the extrusion processability of the sheet and lowering the surface hardness of the finished product to provide a softening effect and improving moisture resistance and aging resistance.

At this time, there are aromatic types, naphthenic types and paraffin type as the type of process oil. In the present invention, it is preferable to use paraffin type process oil having good compatibility with polyolefin type resin.

The specific contents of the above materials are as follows.

Firstly, the antioxidant is added to the resin mixture in an amount of 0.2 to 0.5 phr. When an antioxidant of less than 0.2 phr is added, the chains of the materials added to the resin mixture are broken by heat, resulting in discoloration and deterioration of water resistance. When the content exceeds 0.5 phr, But the manufacturing cost is increased and the physical properties are lowered.

Then, 0.2 to 0.5 phr of zinc stearate is added to the resin mixture. When zinc stearate of less than 0.2 phr is added, the viscosity of the mixture is not sufficiently controlled and there is a problem that the sheet extrusion process is not smooth. On the other hand, when the addition amount of zinc stearate is more than 0.5 phr, excessive lubricating action occurs, .

Further, the ethylene vinyl acetate copolymer is added in an amount of 30 to 40 phr to the resin mixture. When an ethylene vinyl acetate copolymer of less than 30 phr is added, the solubility, flexibility, adhesiveness and foaming property of the solvent deteriorate. When it exceeds 40 phr, the tensile strength is lowered as the melt viscosity is lowered, .

Then, 100 to 200 phr of calcium carbonate is added to the resin mixture. When less than 100 phr of calcium carbonate is added, there is a problem that the seatability and flame retardancy of the sheet are lowered. When the content is more than 200 phr, the effect is similar to that in the case of using the content within the above range, There is a problem that the physical properties are deteriorated.

Further, the process oil is added to the resin mixture in an amount of 5 to 8 phr. When less than 5 phr of process oil is added, compatibility with other resins is lowered and sheet extrusion processing is not smooth. On the other hand, when it exceeds 8 phr, the softening effect is excessive, There is a problem.

Next, referring to the second step (S200), a foaming agent is added to the resin mixture and foamed to produce a lower-layer sheet portion.

On the other hand, the foaming method is classified into a physical foaming method and a chemical foaming method. The chemical foaming method is a method in which a gas generated by thermal decomposition of a foaming agent forms a cell (foam cell, bubble) in a polymer to form a foam And physical foaming is a method of forming a cell by filling the molten polymer with water, freon, nitrogen gas or the like.

In the present invention, it is preferable to use an azodicarbonamide (ADCA, (NH 2 CON) 2) based foaming agent which has a high decomposition temperature and does not readily cause early foaming.

Next, referring to the third step (S300), an upper layer carpet is manufactured using polypropylene yarn.

Specifically, the polypropylene yarn in the third step (S300) may be a high-fineness polypropylene yarn of 2,600 to 2,800 denier manufactured by yarn-spun yarn of 1,300 to 1,400 denier low-isotactic polypropylene, respectively.

In this case, when a low-fineness polypropylene yarn of less than 1,300 denier is used, there is a problem that the strength of the low-fineness polypropylene yarn exceeds 1,400 denier. There is a problem that the uniformity of the fineness decreases due to the insufficient capacity of the sheet extruder and the physical properties become unstable.

When a high-fineness polypropylene yarn of less than 2,600 denier is used, there is a problem that a large amount of yarn is cut off during the yarn winding and twisting process. When using high-fineness polypropylene yarn exceeding 2,800 denier, The uniformity of the fineness is reduced and the physical properties are unstable.

Furthermore, it is possible to further provide an antibacterial agent and a flame retardant agent in the first step (S100) or the third step (S300) to provide a functionality suitable for a vehicle mat.

Particularly, it is possible to impart flame retardancy to the automotive mat by further adding calcium carbonate to the resin mixture in the first step (S100). However, in order to give even better flame retardancy, in the first step (S100), ammonium polyphosphate polyphosphate, APP) can be added to the resin mixture in an amount of 20 phr.

Next, in a fourth step S400, a lower layer sheet portion and an upper layer carpet portion are laminated using a hot-melt film adhesive made of a polyolefin-based elastomer.

Here, the use of the hot-melt film adhesive made of the polyolefin-based elastomer is intended to improve the adhesion of the lower layer sheet portion made of the polyolefin-based resin and the upper layer carpet made of the polypropylene yarn, and it is preferable to use the laminating adhesive bonding method Do.

The automotive mat manufactured by the above-described method is advantageous in that industrial waste is not generated because the automotive mat can be recycled as a separate lower-layer sheet portion by pulverizing and extruding it when it is discarded after a predetermined period of time.

Hereinafter, the present invention will be described in more detail with reference to experimental examples.

Before describing the following experimental examples, resin mixtures each comprising two polyolefin elastomers and two polypropylenes were prepared to select polyolefin elastomers and polypropylene most suitable for a vehicle mat, and the physical properties thereof were compared. Then, by adding the antioxidant, zinc stearate, ethylene-vinyl acetate copolymer, calcium carbonate, process oil and antibacterial agent to the resin mixture containing the two polyolefin elastomers and the two polypropylene, Respectively.

<Experimental Example 1>

In Experimental Example 1, the basic properties of a polyolefin elastomer and a polypropylene, which are base polymers of a resin mixture, were examined.

8150 and 8180 manufactured by Dow Chemical Company were used as the polyolefin elastomer, and Q100f and Q300f manufactured by Lion Del Basel Company were used as the polypropylene. Irganoz 1010 from Ciba-Geigy was used as an antioxidant, and zinc stearate was used as a lubricant.

Here, 8150 and 8180 manufactured by Dow Chemical Co., Ltd. were manufactured including Ethylene-1-octene copolymer, but their physical properties are different due to manufacturing conditions and other additives. Q100f and Q300f manufactured by Lion Del Basel Co., Conditions, and other additives, which are different from each other in physical properties.

The physical properties of the polyolefin elastomers 8150 and 8180 and polypropylene Q100f and Q300f are shown in Table 1, and the table for confirming the basic properties of the polyolefin elastomer and the polypropylene is shown in Table 2.

division Density, g / cm3 Melt Index Hardness
(Shorea) Melting Point (° C) The polyolefin-based elastomer 8150 0.86 0.5 70 55 8180 0.86 0.5 63 47 Polypropylene Q100f 0.88 0.6 30D 140 Q300f 0.89 0.8 36D 160

division POE-1 POE-2 TPO-1 TPO-2 8150 100 8180 100 Q100f 100 Q300f 100 Antioxidant 0.3 Zinc stearate 0.3

The materials of Table 2 were mixed at a temperature of 130 to 160 ° C for 5 minutes using a 5-inch mixing roll, and then molded into a film to prepare specimens of a certain standard, and tensile strength and elongation were measured to compare their physical properties.

2, the tensile strength of POE-1 of about 97kg / cm ^{2, POE-2} has appeared to 35kg / cm ^2, the TPO-1 is 100kg / cm ^2, the TPO-2 is 120kg / cm ² , TPO-2 showed the highest tensile strength among POE-1, POE-2, TPO-1 and TPO-2.

3, the elongation rates of POE-1 and POE-2 were more than 800%, and the elongation rates of TPO-1 and TPO-2 were 400 to 500% Which is very low.

That is, it is preferable that the polypropylene is more excellent in tensile strength and the elongation is better in polyolefin-based elastomer, so that they are mixed and used in order to compensate for the disadvantages of each other.

<Experimental Example 2>

In Experimental Example 2, the physical properties of a lower sheet portion made of a resin mixture further containing EVA are to be confirmed.

The materials and mixing conditions used in Experimental Example 1 were the same, EVA of Hanwha Chemical Co. was further added, and the physical properties of EVA were as shown in Table 3, and a concrete formulation table is shown in Table 4.

Item unit Representative value Melt Index (MI) g / 10 min 4.5 Vinyl acetate (VA) content % 26 density g / cm3 0.949 Vicat softening point ℃ 48 The melting temperature (Tm) ℃ 76

division POE-3 POE-4 TPO-3 TPO-4 8150 65 8180 65 Q100f 65 Q300f 65 EVA 35 Antioxidant 0.3 Zinc stearate 0.3

As shown in FIG. 4, the tensile strength of the polyolefin elastomer was slightly lower than that before EVA was added, and it was confirmed that the polyethylene also had a tensile strength lower by about 10% than that before EVA was added.

The average hardness of each lower sheet portion made of the above resin mixture was 20D shore, and a slight soft characteristic was exhibited.

As shown in FIG. 5, the elongation percentage of the polyolefin elastomer was as high as 850 to 950%, and the elongation percentage of the polypropylene was as low as 350 to 450%.

Accordingly, it is preferable to produce a lower sheet portion having a softness, a tensile strength and a high elongation by mixing a polyolefin elastomer having a low tensile strength and a high tensile strength but low elongation when 35 EVOH is added .

<Experimental Example 3>

In Experimental Example 3, the properties of a lower sheet portion made of a resin mixture containing calcium carbonate and EVA are to be confirmed.

The materials and mixing conditions used in Experimental Example 2 were the same, and calcium carbonate was further added. The physical properties of calcium carbonate are shown in Table 5, and a concrete formulation table is shown in Table 6.

Item value Average particle diameter (占 퐉) 5 DOP absorption (ml / 100g) 50.00 Specific gravity (g / ml) 0.70 Whiteness (%) 97.00 pH 9.80

division POE-5 POE-6 TPO-5 TPO-6 8150 65 8180 65 Q100f 65 Q300f 65 EVA 35 Calcium carbonate 200 Antioxidant 0.3 Zinc stearate 0.3

As shown in FIG. 6, the tensile strength of the polyolefin elastomer was 40 to 50 kg / cm 2, and the tensile strength of the polypropylene was about 60 kg / cm 2, which is a somewhat lower value than that before the addition of calcium carbonate .

As shown in FIG. 7, the elongation percentage of the polyolefin elastomer was as high as about 400 to 500%, and the elongation percentage of the polypropylene was as low as 120 to 220%.

That is, the addition of calcium carbonate showed low values of POE-5, POE-6, TPO-5 and TPO-6 in tensile strength. However, the addition of calcium carbonate prevented the seizure, It is preferable that 200 phr is added.

<Experimental Example 4>

In Experimental Example 4, the physical properties of the lower sheet portion made of the resin mixture further including the process oil, calcium carbonate and EVA are to be confirmed.

The material and mixing conditions used in Experimental Example 3 were the same, and the process oil of P-5 of Myung Chang Petroleum Company was further added. The properties of the process oil are as shown in Table 7, and a concrete formulation table is shown in Table 8.

Item value Specific Gravity (15/4 ℃) 0.891 Flash point (℃) 286 Pour Point (℃) -12.5 Kinematic viscosity (40 ° C) cSt 164.0 Color ASTM L 1.5 Anilan point (° C) 115.0 The refractive index (D ²⁰ n) 1.4890 Viscosity Specific Gravity 0.816
Hydrocarbon composition
Ca 5.0 Cn 31.0 Cp 64.0

division POE-7 POE-8 TPO-7 TPO-8 8150 65 8180 65 Q100f 65 Q300f 65 EVA 35 Calcium carbonate 200 Process oil 6 Antioxidant 0.3 Zinc stearate 0.3

As shown in FIG. 8, the tensile strength of the polyolefin elastomer was 40 to 45 kg / cm 2, and the tensile strength of the polypropylene was about 50 to 60 kg / cm 2, .

As shown in FIG. 9, the elongation percentage of the polyolefin-based elastomer was about 350 to 400%, and the elongation percentage of the polypropylene was about 80 to 120%.

Therefore, it is desirable that the process oil is added to the resin mixture in an amount of 6 phr to maintain adequate tensile strength for use of the automotive mat, but to provide adequate softness and elongation.

<Experimental Example 5>

In Experimental Example 5, the cell of the lower sheet portion according to the content of the foaming agent is to be compared.

After mixing with the same materials and mixing conditions used in Experimental Example 4, azodicarbonamide (ADCA, (NH2CON) 2) based foaming agent was further added and foamed at a temperature of 200 to 220 ° C .

Here, only the polyolefin-based elastomer in the base polymer of the resin mixture was tested. Physical properties of the foaming agent are shown in Table 9, and specific formulation tables are shown in Table 10.

Item value Appearance Orange-based fine powder Decomposition temperature (℃)
(5 DEG C / min in air) 201-205 capillarity 200 Gas volume (ml / g) 215 to 225 @ STP (280 to 300 in air) Humidity(%) 0.3 MAX pH 6.5 to 7.0 Average particle diameter 16-18

division FO-1 FO-2 FO-3 FO-4 8150 65 EVA 35 Calcium carbonate 200 Process oil 6 Antioxidant 0.3 Zinc stearate 0.3 blowing agent One 2 3 4

Referring to FIG. 11, FO-1 to FO-3 to which 1 to 3 phr of blowing agent was added were inadequate because of a small number of cells formed, and FO-4 to which 4 phr of blowing agent was added had the highest number of cells, Respectively.

That is, it is preferable that 4 phr of blowing agent is added. As shown in FIG. 10, since the decomposition temperature of the blowing agent used in this experiment is 200 ° C. or higher, it is most preferable to foam at a temperature within the range of 200 to 220 ° C. for 2 to 4 minutes Suitable.

In addition, according to the results of the above-described experimental examples, it is confirmed that 8150 produced by Wako Chemical Co., Ltd. is suitable as the polyolefin-based elastomer, and Q100f manufactured by Lion Del Basel is suitable as the polypropylene.

<Experimental Example 6>

In Experimental Example 6, the antimicrobial activity of the lower sheet portion to which the antimicrobial agent was added was examined.

The materials and mixing conditions used in Experimental Example 5 were mixed in the same manner, and then a lower sheet portion was prepared. Three antimicrobial agents were added to the mixture to observe the growth of the bacteria in the medium, and the antimicrobial activity was confirmed.

Table 11 shows the types of the three kinds of antimicrobial agents. Table 12 shows the conditions of the antimicrobial test using the medium.

Antimicrobial agent product AI component (%) Solid content (%) Sodium Dimethyldithiocarbamate
(SDD) P 40.9 43.6 Potassium Dimethyldithiocarbamate
(PDD) B 49.3 55 Potassium-hydroxymethyl-
methyldithiocarbamate (PHMD) T 18 20

Referring to Table 11, the product P refers to the vehicle mat of the present invention prepared by adding the antimicrobial agent SDD, the product B refers to the vehicle mat of the present invention prepared by adding the antimicrobial agent PDD, and the product T contains the antibacterial agent PHMD The mat for a vehicle according to the present invention.

Selection of badge NA (Nutrient agar), NB (Nutrient broth), LB (Luria-bertani) broth
⇒ Selection of medium suitable for growth of bacteria (LB is suitable) Sterilization after preparation of medium High-pressure sterilization at Autocleave Test culture - Culture in liquid medium (NB) (shaking bath: 30 ~ 37 ℃, Overnight)
- Test bacteria: Escherichia coli , Staphylococcus aureus Badge smear The cultured test bacteria were plated on glass Sample setting Place the antimicrobial fabric on the medium. Incubator Culture 30 ~ 37 ℃, Overnight (12h, 18h, 24h check) clear zone check Measure length of retaining ring from fabric in mm

12a and 12b, the antimicrobial activity against Escherichia coli was measured by the clear zone size. As a result, it was found that the blank had no antibacterial activity and the antibacterial activity of the P product and the T product hardly appeared , And Potassium Dimethyldithiocarbamate (PDD), the product of B, showed the best antibacterial activity.

<Experimental Example 7>

In Experimental Example 7, an adhesive suitable for improving the adhesive strength between the lower layer sheet portion and the upper layer sheet portion was selected.

The lower layer sheet portion and the upper layer sheet portion were produced under the same conditions as those in Experimental Example 6, and then bonded with eight kinds of adhesives, and then the bonding strengths were compared with each other.

Table 8 shows the types of the eight adhesives.

division KA-1 KA-2 KA-3 KA-4 Adhesive Type Polyurethane system
Hot melt film Alpha olefin series
Hot melt film Polypropylene
Hot melt film EVA
Hot melt film division KA-5 KA-6 KA-7 KA-8 Adhesive Type EVA emulsion PUD emulsion Acrylic emulsion POD emulsion

Referring to FIG. 13, the adhesive strength of KA-2 was the best.

14A, the front surface of the automobile mat, which is formed by molding an automobile mat with an alpha-olefin hot melt film, in accordance with each vehicle model, and the back surface thereof can be confirmed with reference to FIG. 14B .

15A, the front surface of the automobile mat, which is formed by molding and matting the automotive mat with the alpha olefin based hot melt film according to each vehicle type as in Experimental Example 7, can be confirmed. . Particularly, embossed molding is possible on one surface of the lower-layer seat portion which abuts against the bottom of the vehicle to prevent slippage.

<Experimental Example 8>

In Experimental Example 8, a mat for a vehicle, which was produced in the same manner as in Experimental Example 7, was pulverized and melted to produce a recycled sheet, and then the physical properties of the recycled mat and the vehicle mat of the present invention were compared.

First, the automotive mats of the present invention were pulverized into a fillet size, melted and dispersed in an extruder, and subjected to T-die processing to produce a recycled sheet. The conditions of the extruder for producing the recycled sheet are shown in Table 14, and the recycled sheet thus produced can be confirmed from FIG.

division CY1 CY2 CY3 CY4 CY5 CY6 CY7 CY8 DIE RPM Condition 120 DEG C 147 ℃ 150 ℃ 137 ℃ 137 ℃ 158 C 150 ℃ 153 ℃ 182 DEG C 230

At this time, it is preferable to use a single screw extruder, which is a type of mixer capable of mixing effectively. The processing conditions of the uniaxial extruder are barrel length and diameter ratio (L / D), screw shape, screw rotation speed (rpm), and processing temperature. The conditions in Table 14 were determined by considering the kneading effect and the productivity simultaneously.

Physical properties of the recycled sheet and the vehicle mat of the present invention are as shown in FIG. 17 to FIG. 19, the recycled sheet is denoted by RE-1, and the automotive mat of the present invention is denoted by POE-1.

First, as shown in FIG. 17, RE-1 was about 45 kg / cm and POE-1 was 30 kg / cm, showing a higher RE-1.

As shown in FIG. 18, the elongation was POE-1 of 800% and RE-1 of 400%, indicating higher POE-1.

Finally, as shown in FIG. 19, the surface hardness was about 85 shore A for RE-1 and about 77 shore A for POE-1, indicating that RE-1 was higher.

These results suggest that the mechanical properties of polypropylene used as a raw material for fiber are increased.

The polyolefin elastomer is widely used as a thermoplastic elastomer due to its wide hardness range, weatherability, low cost, high compatibility with various polyolefin materials, easy recyclability, and environmentally friendly characteristics, and it accounts for about 35% of the total thermoplastic elastomer market It is occupied.

The polyolefin elastomer is used as an automobile airbag cover, an interior skin, an instrument panel, a tube, a pipe, a film and a PVC substitute, but has disadvantages such as low elasticity, scratch resistance, poor heat resistance, low tackiness and paintability.

In order to solve the disadvantages of the above-mentioned polyolefin-based elastomer, in the present invention, a lower layer sheet portion is prepared from a resin mixture comprising a polyolefin elastomer and polypropylene, an upper layer carpet portion is made of polypropylene yarn, and an adhesive made of a polyolefin- The adhesive strength can be improved.

Since polyolefin elastomer and polyolefin, which is one of polyolefin materials, do not emit volatile organic compounds, consumers can use it comfortably as well as the working environment, and they can be crushed and extruded entirely without being separated at the time of disposal, It is environmentally friendly and has the advantage of not producing industrial waste.

Claims (5)

A first step of preparing a resin mixture comprising a polyolefin elastomer and a polypropylene in a mixing ratio of 1: 1;
A second step of adding a foaming agent to the resin mixture to produce a lower-layer sheet part through thermal decomposition of the foaming agent within a temperature range of 200 to 220 占 폚;
A third step of producing an upper layer carpet portion by using a polypropylene yarn; And
And a fourth step of joining the lower-layer sheet portion and the upper-layer carpet portion using a hot-melt film adhesive made of a polyolefin-based elastomer,
The blowing agent may contain,
And an azodicarbonamide (ADCA, (NH ₂ CON) ₂ ) system having a thermal decomposition temperature of 200 ° C or higher,
The above-
Wherein at least one of ethylene-vinyl acetate copolymer (EVA), from 100 phr to 200 phr of calcium carbonate and from 5 phr to 8 phr of process oil is applied to the resin mixture in an amount of 30 phr to 40 phr (phr: parts per hundred resin) Wherein the polyolefin-based resin is used as a raw material for a vehicle. The method according to claim 1,
The resin mixture prepared in the first step further contains an antioxidant and zinc stearate,
Wherein the content of the antioxidant and the zinc stearate is 0.2 to 0.5 phr, respectively, with respect to the resin mixture, and the recycled material can be recycled by unitizing the material using the polyolefin resin. delete The method according to claim 1,
In the third step,
Wherein the polyolefin resin is a high-fineness polypropylene yarn of 2,600 to 2,800 denier, which is produced by subjecting low-fineness polypropylene yarns of 1,300 to 1,400 denier to yarn-folding and twisting, respectively, to produce recyclable mats. A mat for a vehicle manufactured by the method of any one of claims 1, 2, and 4 is pulverized and extruded to be recycled as a separate lower layer sheet part. mat.

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